1. 5 critical areas in Cement plants
Small, but vital for the process:
Burner pipe
Nose ring
Bull Nose
T.A. Duct damper
Coating in smoke chamber
5 critical areas in Cement plants

2. 5 critical areas in Cement plants
The burner pipe is consuming very little refractory, but a failure can stop the entire process for many hours.
The use of alternative fuels and high sulphur coal, have challenged the quality of refractories, but also the installation and quality of anchors.
Clinker and sometimes big pieces of coating can fall on top of the burner.
Heavy stream of clinker dust from the secondary air is coursing heavy wear on the bottom of the burner.
Too often we see the burner pipe in this mood.

3. Burner pipe

7. 5 critical areas in Cement plants
Burner pipe after 1 year
5 critical areas in Cement plants

8. 5 critical areas in Cement plants
Burner pipe after 1 year
5 critical areas in Cement plants

9. 5 critical areas in Cement plants
Burner pipe
5 critical areas in Cement plants

10. 5 critical areas in Cement plants
Nose ring

11. 5 critical areas in Cement plants
The nose ring casting is protecting the tip of the kiln. SS castings are protecting
the kiln shell. On top of these and sometimes on front, LCC is installed.
Clinker is sliding on the nose ring castable, which challenge the wear resistance.
Ovality of the kiln end course stress at the castable, if prober expansion is not taken care of.
Cooling air for the SS castings is coursing temperature difference in the LCC. Thermal shock resistance of the LCC is required.

12. 5 critical areas in Cement plants
Castable failure at the Nose Ring

13. 5 critical areas in Cement plants

14. 5 critical areas in Cement plants Bull Nose.
Exposed to heavy heat from the first grate clinker bed, heavy wear from clinker dust, high temperature and mechanical forces due to the steel support.

15. 5 critical areas in Cement plants

16. 5 critical areas in Cement plants

17. 5 critical areas in Cement plants

18. 5 critical areas in Cement plants
T.A. duct damper
The damper control the tertiary air to the calciner. Normally it consists of a steel plate covered by refractory material to withstand the wear from high velocity dust.
Very often the castable is worn out in a few months and the steel plate
Will start to burn and buckle. By this, the tertiary air cannot be adjusted.
A choice of highly wear resistant LCC combined with allowance for the thermal expansion of the steel plate can extend the life.

19. 5 critical areas in Cement plants

20. T.A. duct damper
5 critical areas in Cement plants

21. T.A. duct damper
5 critical areas in Cement plants

22. 5 critical areas in Cement plants
T.A, duct damper

23. 5 critical areas in Cement plants
T.A. duct damper

24. 5 critical areas in Cement plants
T.A. duct damper

25. 5 critical areas in Cement plants
Coating formation in smoke chamber and riser duct.
Coating forms by the process, we cannot avoid that.
Today's use of all kind of alternative fuels have increased the aggressive chemical
attack on most refractory materials in the market.
But by use of low porosity refractory, with a raw material composition which
do not allow the coating to stick to the lining, we can reduce or eliminate the
production loss.
Coating will form but slide off by its own gravity or by help from external force,
air blasters or poking.

26. 5 critical areas in Cement plants
Coating formation in smoke chamber and riser duct
HASLE LCC
Other supplier

27. 5 critical areas in cement plant

28. 5 critical areas in cement plant

29. 5 critical areas in cement plant
The mentioned areas are some of those we normally focus on.
A combination of superior qualities and close teamwork with agent and the end-user, we are able to further increase the refractory life.

30. 5 critical areas in cement plant
agent
agent
agent
agent

31. Thank you.